Method for embedding images in soap

ABSTRACT

A method of producing a solid soap containing at least one image embedded within the solid soap includes printing a printed image on a base layer of solid soap, applying molten soap to the printed base layer, and allowing the soap to harden so as to embed the image within the solid soap. The image can be a high-resolution image and can be printed on the base layer of solid soap using a flatbed printer. The soap can include a background layer against which the image is visible.

CROSS-REFERENCE TO A RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/916,871, filed Mar. 9, 2018; which claims priority to Canadian PatentApplication No. 2,992,185, filed Jan. 17, 2018, both of which areincorporated herein by reference in their entirety.

BACKGROUND

The present application is directed to a method of embedding an imageinto soap. More specifically, the present application relates to amethod for embedding a high-resolution image layer into solid soap.

Soaps containing one or more embedded images may be useful foradvertising, souvenirs, decoration, or a variety of other noveltypurposes. However, images located on the exterior surface of the soapmight quickly deteriorate or disappear as the soap is used and graduallydissolved. In contrast, images embedded into the interior of soap can beprotected from conditions that could damage or erode the image and thusmay provide a longer-lasting experience to the user. For example, animage embedded in a transparent or translucent bar of soap may remainvisible to the user until the soap has been almost completely used.Alternatively, an image embedded in an opaque bar of soap may remainhidden until gradual dissolution of the soap during use exposes theimage. In such a case, for example, the exposed image may reveal anadvertising message such as “Time to replace the [specific brand of]soap”, or any other desired message or image.

Methods of embedding images into soap are described in U.S. Pat. Nos.6,720,296; 6,184,191; 6,136,764; 5,869,437; 1,827,549; and RE6624.However, embedding soap with a solid image-bearing substrate such asplastic or cardboard can result in injury or discomfort to the user ifthe plastic or cardboard substrate is exposed as the soap wears awayduring use. In addition, known methods can result in images which areblurry, of low definition or otherwise poor quality, or which may bleedinto the surrounding soap.

Thus, new methods are desirable for producing soap with one or moredissolvable embedded images having one or more of the followingcharacteristics: high-quality, multicolour, long-lasting, crisp, robust,and resistant to degradation or bleeding over time.

SUMMARY

The present application provides a method for preparing a solid soapcontaining at least one embedded image. The method includes printing aprinted image on a dissolvable substrate to form an image layer, whereinthe dissolvable substrate is printable at high-resolution, bringing theimage layer into contact with molten soap, and allowing the molten soapto harden so as to embed the image layer within the solid soap. In atleast one embodiment, the printed image is a high-resolution image. Inat least one embodiment, the printed image is a photo-quality image. Inat least one embodiment, the printed image is a three-dimensional image.

In at least one embodiment, the dissolvable substrate is a dried pastecomprising water, one or more starches, starch sources or modifiedstarches, one or more sugars or sugar sources, oil or fat, at least oneemulsifier and at least one stabilizer. In at least one embodiment, thedried paste further comprises one or more components selected from apolyhydric alcohol, a preservative, a flavouring agent, a colouringagent and an opacifying agent. In at least one embodiment, thedissolvable substrate is a printable icing or frosting sheet.

In another aspect, the present application provides the use of an imagelayer as described herein for preparing a solid soap containing at leastone embedded image. A further aspect provides a solid soap containing atleast one embedded image prepared by the method described herein.

DEFINITIONS

As used herein, the terms “about” or “approximately” as applied to anumerical value or range of values are intended to mean that the recitedvalues can vary within an acceptable degree of error for the quantitymeasured given the nature or precision of the measurements, such thatthe variation is considered in the art as equivalent to the recitedvalues and provides the same function or result. For example, the degreeof error can be indicated by the number of significant figures providedfor the measurement, as is understood in the art, and includes but isnot limited to a variation of ±1 in the most precise significant figurereported for the measurement. Typical exemplary degrees of error arewithin 20 percent (%), preferably within 10%, and more preferably within5% of a given value or range of values. Numerical quantities givenherein are approximate unless stated otherwise, meaning that the term“about” or “approximately” can be inferred when not expressly stated.

As used herein, the term “substantially” refers to the complete ornearly complete extent or degree of an action, characteristic, property,state, structure, item, or result. For example, an object that is“substantially” in a given position including but not limited tovertical, horizontal, or adjacent to or aligned with another object,would mean that the object is either completely in that position ornearly completely in that position. The exact allowable degree ofdeviation from absolute completeness may in some cases depend on thespecific context. However, generally speaking the nearness of completionwill be so as to have the same overall result as if absolute and totalcompletion were obtained.

The use of “substantially” is equally applicable when used in a negativeconnotation to refer to the complete or near complete lack of an action,characteristic, property, state, structure, item, or result. Forexample, an image that undergoes “substantially no” degradation wouldeither completely lack degradation, or so nearly completely lackdegradation that the effect would be the same as if it completely lackeddegradation. In other words, an image that undergoes “substantially no”degradation may still actually undergo some minor degradation as long asthere is no measurable or significantly noticeable effect thereof.

As used herein, terms indicating relative direction or orientation,including but not limited to “upper”, “lower”, “top”, “bottom”,“vertical”, “horizontal”, “outer”, “inner”, “front”, “back”, and thelike, are intended to facilitate description of the present invention byindicating relative orientation or direction in usual use, and are notintended to limit the scope of the present invention in any way to suchorientations or directions.

DETAILED DESCRIPTION

The present application provides a method for preparing a solid soapcontaining at least one embedded image. As used herein, the term “solidsoap” is intended to refer to soap which is in a solid state when atroom temperature. As used herein, the term “soap” is intended to referto alkali metal salts of fatty acids, including but not limited tosodium and potassium salts of fatty acids, and formulations containingsuch alkali metal salts of fatty acids. Fatty acids include but are notlimited to saturated and unsaturated C₁₂₋₁₈ alkanoic acids, includingbut not limited to lauric acid, myristic acid, palmitic acid, stearicacid, oleic acid, linoleic acid, and linolenic acid.

The soap may be in any solid form, including but not limited to slabs,sheets, or individual bars or cakes which are round, rectangular, oval,or any other shape which can be produced with a mold, by cutting from aslab or sheet, by three-dimensional printing, or by other suitablemethods known in the art. The individual bars or cakes can be of anysize convenient for use, including but not limited to soap sheets, soapleaves, hotel-size soaps, guest soaps, standard personal-size soap barsand laundry-size soap bars, as will be understood by the skilled person.In embodiments, the amount of soap in the individual bar or cake canrange from about 1 gram or less to about 450 grams or more, and thedimensions of the individual bar or cake can range from about 1 mm orless to about 8 cm or more in thickness and from about 2 cm or less toabout 15 cm or more in one or more of length, width or diameter. In atleast one embodiment, the soap can be a large slab or sheet having amass of up to several hundred kilograms or more and having dimensions upto several meters, from which individual bars or cakes can be cut. Suchlarge slabs or sheets can be prepared during manufacture of the soap, orfor promotional purposes, and the individual bars or cakes can be cutand provided to customers on demand. The person of skill in the artwould be aware of other possible configurations of the present solidsoap having other possible dimensions and amounts of soap.

The soap may be transparent, translucent, or opaque. Suitable soapformulations may include natural and synthetic additives, including butnot limited to detergents, surfactants, glycerol or glycerin, oils orfats, emollients, exfoliants, colours, fragrances, antimicrobial agents,decorative elements and other additives well known in the art. Suitablesoaps and soap formulations are commercially available or can be readilymade by known procedures, including but not limited to saponification ofoils and fats by reaction with strong bases, including but not limitedto sodium hydroxide or lye.

The method includes printing an image on a dissolvable substrate to forman image layer. As used herein, the term “image” is intended to refer toany two-dimensional graphical representation. This may include, but isnot limited to, photographs, drawings, illustrations, text matter orother graphical depictions, and can be in black and white or in one ormore colours. Suitable images can be produced on or applied to a surfaceusing any suitable methods known in the art, including but not limitedto ink jet printing, xerography, gravure, screen printing, or othermethods which are known in the art. The image can be of any sizesuitable for the size of the soap into which the image will be embeddedsuch that it is visible to a user of the soap, as will be understood inthe art.

In at least one embodiment, the image is a high-resolution image. Thus,the dissolvable substrate is capable of being printed with ahigh-resolution image, although an image selected for embedding in thesolid soap need not be a high-resolution image. As used herein, the term“high-resolution image” is intended to refer to a colour or black andwhite image printed by a high-resolution printer. A suitablehigh-resolution printer is capable of printing with a print resolutionof at least 150 dots per inch (dpi), or of at least 300 dpi, and may becapable of printing with a print resolution of up to 2400 dpi or up to4800 dpi or up to 9600 dpi or higher. The printer can be capable ofprinting the image using any suitable printing process known in the art,including but not limited to three-colour process, four-colour process,monotone or spot colour.

In at least one embodiment, the image is a photo-quality image. As usedherein, the term “photo-quality image” is intended to refer to ahigh-resolution image in full colour, such that the photo-quality imageis substantially similar to a full colour photographic image whenviewed.

In at least one embodiment, the image or high-resolution image is athree-dimensional image. As used herein, the term “three-dimensionalimage” is intended to mean a two-dimensional image that can be printedon a dissolvable substrate as described herein, but which gives a visualimpression of depth in a third dimension. Examples of three-dimensionalimages include but are not limited to stereoscopic images andholographic images in addition to images, including but not limited tohigh-resolution images, which have a composition and/or quality whichgives a visual impression of depth in a third dimension.

The dissolvable substrate is printable at high-resolution to form theimage layer. As used herein, the term “printable at high-resolution” isintended to refer to the ability to be printed with a high-resolutionimage such that the resulting printed image substantially retains thedegree of resolution at which the high-resolution image is printed. Inat least one embodiment, when an image, including but not limited to ahigh-resolution image, a photo-quality image or a three-dimensionalimage, has been embedded in the solid soap according to the presentmethod, the embedded image is advantageously resistant to at least oneof bleeding, blurring and degradation. In at least one embodiment, theimage remains crisp and clear with substantially no or only minimallydetectable degradation, bleeding or blurring for a period of at least 6months, or at least 1 year, or at least 3 years, or at least 5 years.

In at least one embodiment, the dissolvable substrate comprises a solidpaste comprising water, one or more starches, starch sources or modifiedstarches, one or more sugars or sugar sources, oil or fat, at least oneemulsifier and at least one stabilizer. In at least one embodiment theone or more starches, starch sources or modified starches include butare not limited to one or more of corn starch, tapioca starch, glutinousrice, distarch phosphate, acetylated distarch adipate, and maltodextrin.In at least one embodiment, the one or more sugars or sugar sourcesinclude but are not limited to one or more of sugar, glucose, dextrose,fructose, sucrose, corn syrup solids and corn syrup. In at least oneembodiment, the oil or fat is an edible oil or fat, including but notlimited to a vegetable oil or hydrogenated coconut fat. In at least oneembodiment, the emulsifier includes but is not limited to amonoglyceride of a fatty acid, a diglyceride of a fatty acid, a sorbitanester and a polysorbate nonionic surfactant. In at least one embodiment,the sorbitan ester includes but is not limited to sorbitan monostearate.In at least one embodiment, the polysorbate nonionic surfactant includesbut is not limited to one or more of polyoxyethylene sorbitantristearate, polysorbate, polysorbate 60 and polysorbate 80. In at leastone embodiment, the stabilizer is one or more of a gum and cellulose. Inat least one embodiment, the gum includes but is not limited to gumarabic and acacia gum. In at least one embodiment, the celluloseincludes but is not limited to microcrystalline cellulose.

In at least one embodiment, the dissolvable substrate further contains apolyhydric alcohol, including but not limited to one or more ofglycerol, glycerin and sorbitol. Other ingredients well known in the artmay also be present in the dissolvable substrate, including but notlimited to preservatives, flavouring agents, colouring agents andopacifying agents. Suitable preservatives include but are not limited tocitric acid, sorbitol and potassium sorbate. Suitable flavouring agentsinclude but are not limited to artificial sweeteners, and well-knownflavouring agents, including but not limited to vanilla flavouring.Suitable artificial sweeteners include but are not limited to sucralose.Suitable colouring agents include but are not limited to food gradecolouring agents. Suitable opacifying agents include but are not limitedto titanium dioxide.

In at least one embodiment, the dissolvable substrate comprises a solidpaste comprising water, cornstarch, glutinous rice, glucose, sugar,vegetable oil, arabic gum, polysorbate 60, citric acid and vanillaflavouring. In at least one embodiment, the dissolvable substratecomprises a solid paste comprising water, corn starch, corn syrup, cornsyrup solids, cellulose, sorbitol, glycerin, sugar, vegetable oil, gumarabic, polysorbate 80, vanilla, titanium dioxide and citric acid. In atleast one embodiment, the dissolvable substrate comprises a solid pastecomprising starches (distarch phosphate, acetylated distarch adipate),maltodextrin, glycerin, sugar, water, acacia gum, microcrystallinecellulose, dextrose, emulsifiers (polyoxyethylene sorbitan tristearate,mono and diglycerides of fatty acids, sorbitan monostearate), titaniumdioxide, sucralose, citric acid, flavours, preservative (potassiumsorbate) and hydrogenated coconut fat. In at least one embodiment, thedissolvable substrate comprises a solid paste comprising tapioca starch,corn syrup, corn syrup solids, cellulose, purified water, sugar,vegetable oil, polysorbate, gum arabic, citric acid, sorbitol,glycerine, titanium dioxide and vanilla.

In at least one embodiment, the dissolvable substrate comprises a driedpaste comprising:

-   a) a first base composition comprising 6.4% modified corn starch,    0.4% citric acid, 24.5% sugar, and 68.7% corn syrup solids by    weight;-   b) a second base composition comprising 75.2% corn syrup, 2.3%    titanium dioxide, and 22.5% gum Arabic by weight;-   c) a forming composition comprising 9.1% polysorbate 80, 11.4%    glycerin, and 79.5% vegetable oil by weight; and-   d) a solidifying composition comprising 29.2% microcrystalline    cellulose, 68.7% cornstarch; 0.9% sodium hydroxide and 1.2% clear    vanilla flavor by weight.    The dried paste can be prepared using a procedure described in one    or more of US 2010/0189858, US 2006/0210681, and US 2006/0045947. In    at least one embodiment, the dissolvable substrate comprises a solid    paste comprising 26% tapioca starch, 24% corn syrup, 14% corn syrup    solids, 11% cellulose, 10% purified water, 6% sugar, 2% vegetable    oil, 1% polysorbate, and less than 1% each of gum arabic, citric    acid, sorbitol, glycerine, titanium dioxide and vanilla.

In at least one embodiment, the dissolvable substrate is disposed on aremovable backing layer as described in one or more of US 2010/0189858,US 2006/0210681, and US 2006/0045947. The backing layer can be anymaterial which provides support to the dissolvable substrate, includingbut not limited to during printing of the image on the dissolvablesubstrate, and should be a material from which the dissolvable substratecan be removed without causing damage to the dissolvable substrate or toany image printed thereon. Materials suitable for the removable backinglayer are known in the art and include but are not limited to plastics.

In at least one embodiment, the dissolvable substrate is a printableedible icing or frosting sheet which can be used for decoratingfoodstuffs such as baked goods, desserts and confectionery. Suitableedible icing or frosting sheets are sold or manufactured commercially bysuppliers including but not limited to PhotoFrost, Kopykake Enterprises,Inkedibles, and Edible Image Supplies.

The image is printed on the dissolvable substrate using inks that aresafe for contact with human skin. In at least one embodiment, the imageis printed on the dissolvable substrate using edible inks that are safefor human consumption. In at least one embodiment, the inks comprise oneor more dyes or colorants in a carrier comprising water and one or moreco-solvents or humectants. In at least one embodiment, the dyes orcolorants are food grade dyes or colorants, including but not limited toBrilliant Black BN (E151), azorubine (E122), Ponceau 4R (E124),erythrosine (FD&C Red #3; E127), Allura Red AC (FD&C Red #40; E129),Brilliant Blue FCF (FD&C Blue #1; E133), tartrazine (FD&C Yellow #5;E102), Quinoline Yellow WS (E104) and Sunset Yellow FCF (FD&C Yellow #6;E110). In at least one embodiment, the co-solvent or humectant includesbut is not limited to ethanol, grain alcohol, propylene glycol andglycerin. Other agents such as preservatives, biocides, fungicides,buffering agents, fixatives, penetrants, surfactants, and resins mayalso be present. In at least one embodiment, the preservative includesbut is not limited to one or more of propylene glycol, citric acid andmethylparaben. Suitable inks are described in one or more of US2010/0189858, US 2006/0210681, and US 2006/0045947, or are soldcommercially as edible inks or inks otherwise safe for contact withhuman skin or as inkjet printer-compatible cartridges containing suchedible inks or inks otherwise safe for contact with human skin, bysuppliers including but not limited to PhotoFrost, Kopykake Enterprises,Inkedibles, and Edible Image Supplies.

In at least one embodiment, the image is printed on the dissolvablesubstrate using an inkjet printer containing suitable inks as describedherein. In at least one embodiment, the inkjet printer is ahigh-resolution printer. Suitable inkjet printers include but are notlimited to a printer as described in US 2011/0025735 and Epson™ andCanon™ inkjet printer models which can accept inkjet printer-compatiblecartridges containing suitable inks as described herein. In at least oneembodiment, the inkjet printer is a large format inkjet printer,including but not limited to a flatbed printer.

The method further includes bringing the image layer into contact withmolten soap and allowing the soap to harden so as to embed the imagelayer within the solid soap. The molten soap can be produced by anymethod known in the art, including but not limited to melting a solidsoap base using any convenient heating method. Suitable heating methodsinclude but are not limited to microwaving the soap or heating the soapover hot water or steam.

When the molten soap is brought into contact with the image layer, themolten soap can be at any temperature above its melting point at whichthe viscosity of the molten soap permits the molten soap to flow andspread so as to coat the image layer, but that is low enough to avoiddamage to the dissolvable substrate due to contact with the molten soapand to avoid damage to the soap itself. In view of the teaching herein,the person of skill in the art will be readily able to determine asuitable temperature at which a particular formulation of soap can bebrought into contact with an image layer. In at least one embodiment,the molten soap is at a temperature between about 40° C. and about 100°C. In at least one embodiment, the molten soap is at a temperaturebetween about 40° C. and about 95° C.

In at least one embodiment, the image layer is coated with a dissolvablecoating prior to being brought into contact with the molten soap. In atleast one embodiment, the dissolvable substrate is coated with adissolvable coating and one or more images are printed on thedissolvable substrate pre-coated with the dissolvable coating to formthe coated image layer. In at least one embodiment, the dissolvablesubstrate is printed with one or more images prior to being coated withthe dissolvable coating to form the coated image layer. In at least oneembodiment, the dissolvable coating includes but is not limited to oneor more of shellac and a dissolvable plastic, including but not limitedto polylactic acid, polyglycolic acid and polyvinylalcohol. Othersuitable dissolvable coatings are known or can be prepared by a personskilled in the art.

In at least one embodiment of the present process, the image layer isencased in soap to form a soap-encased image layer. In at least oneembodiment, molten soap is applied to the image layer and allowed toharden. In at least one embodiment, molten soap is applied by pouringthe molten soap onto one side of the image layer. In at least oneembodiment, the amount of molten soap poured onto the image layer is atleast the minimum necessary to entirely cover the image layer so as toform a coherent and stable solid soap layer in contact with the imagewhen the soap hardens. However, the amount of molten soap can be chosento form a thicker solid soap layer on the image layer. In at least oneembodiment, when the soap layer applied to the image layer has hardened,molten soap is poured onto the reverse side of the image layer andallowed to harden so as to encase the image layer in solid soap. Inembodiments in which the image layer has a removable backing layer asdescribed herein, molten soap can be first applied to the exposed sideof the image layer and allowed to harden, then the removable backinglayer can be removed to expose the reverse side of the image layer, andmolten soap can be applied to the exposed reverse side of the imagelayer so as to encase the image layer in solid soap. The soap-encasedimage layer can be cut to a desired shape and size.

In at least one embodiment, the image layer or the soap-encased imagelayer can be applied to a base layer of solid soap. In at least one suchembodiment, the base layer can be prepared by pouring molten soap into amold so as to partially fill the mold, and allowing the molten soap toharden to form the base layer. The base layer can be a sheet or slab ofsoap, or can be molded into individual bars or cakes. In at least oneembodiment, the base layer can be prepared by three-dimensional printingusing a molten soap.

The image layer or the soap-encased image layer is adhered to the baselayer by pouring an adhering layer of molten soap onto the base layer,placing the image layer or the soap-encased image layer on the adheringlayer of molten soap, and allowing the adhering layer of molten soapbetween the base layer and the image layer or soap-encased image layerto harden. In at least one embodiment, the adhering layer of molten soapcontains sufficient molten soap to intimately and strongly adhere theimage layer or the soap-encased image layer to the base layer, as willbe understood in the art.

In at least one embodiment, a background layer can be disposed on thedissolvable substrate to form part of the image layer. The backgroundlayer can be opaque and/or coloured. In at least one embodiment, thebackground layer is a white, opaque layer comprising titanium dioxide.In at least one embodiment, the background layer can be printed on thedissolvable substrate by methods known in the art including, but notlimited to, block printing. In at least one embodiment, when abackground layer has been disposed on the dissolvable substrate, theimage is printed on the background layer, such that the image isapparent against the background layer. In at least one embodiment, afirst image is printed on the dissolvable substrate, a background layeris disposed on the printed dissolvable substrate and a second image isprinted on the background layer. In this way, a two-sided image can beproduced, in which the first image is apparent against a first side ofthe background layer and the second image is apparent against a secondside of the background layer, wherein the second side of the backgroundlayer is opposite to the first side of the background layer. In at leastone embodiment of such a two-sided image, the background layer isopaque, such that only one of the two images would be apparent whenviewing each side of the background layer.

In at least one embodiment, a background layer can be disposed on thebase layer of soap before the image layer is adhered. In at least oneembodiment, the background layer can be printed on the soap base. In atleast one embodiment, the background layer is formed by pouring a layerof molten opaque soap on the soap base and allowing the molten opaquesoap to harden. In such embodiments, the image layer can be adhered tothe hardened layer of opaque soap as described herein.

In at least one embodiment, one or more additional image layers orsoap-encased image layers or background layers as described herein canbe layered on an image layer or soap-encased image layer or backgroundlayer already adhered to the base layer, so as to embed a multi-layerimage into the solid soap. In at least one embodiment, a backgroundlayer can be layered on a previously adhered image layer or soap-encasedimage layer by printing or by pouring a layer of molten opaque soap overthe previously adhered image layer or soap-encased image layer asdescribed herein. In at least one embodiment, an additional adheringlayer of molten soap is added to the previously adhered image layer orsoap-encased image layer or background layer, the additional image layeror soap-encased image layer is placed in contact with the adhering layerof molten soap, and the adhering layer is allowed to harden tointimately and strongly adhere the additional image layer orsoap-encased image layer to the previously adhered image layer orsoap-encased image layer or background layer. The process can berepeated until all desired additional image layers or soap-encased imagelayers or background layers have been adhered to form the multi-layerimage. In at least one embodiment, an intermediate layer of molten soapof varying thickness may be poured over a previously adhered image layeror soap-encased image layer or background layer and allowed to hardenbefore adhering an additional image layer or soap-encased image layer orbackground layer, so as to distance the images or background layers fromeach other within the soap.

In embodiments in which one or more image layers or soap-encased imagelayers have been adhered to a base layer or background layer, a finishlayer of additional molten soap can be poured or three-dimensionallyprinted onto the adhered image layers or soap-encased image layers andallowed to harden so as to provide a solid soap of the desired size andshape. In at least one embodiment, if the amount of soap encasing thesoap-encased image layer is of sufficient thickness to form the presentsolid soap, it may not be necessary to adhere the soap-encased image toa base layer of solid soap, or to add a finish layer onto thesoap-encased image layer.

In embodiments in which one or more image layers or soap-encased imagelayers or background layers are embedded between a base layer of soapand a finish layer of soap, the depths of the base layer and of thefinish layer are chosen such that the resulting image or multi-layerimage has the desired position when embedded within the final solidsoap. In at least one embodiment, the depths of the base layer and thefinish layer can be approximately one-half the desired depth of thefinal solid soap, so that the image can be positioned substantially inthe middle of the final solid soap. In at least one alternativeembodiment, the depths of the base layer and the finish layer can beless than or more than one-half the desired depth of the final solidsoap, so that the embedded image can be closer to one face of the solidsoap than to the opposite face.

In at least one embodiment, an image can be applied to a base layer ofsolid soap by printing the image directly onto the base layer of solidsoap, or onto a background layer disposed on the base layer. In at leastone embodiment, a dissolvable substrate as described herein can beapplied or adhered to the base layer of soap, or onto a background layerdisposed on the base layer, and an image can be printed on the surfaceof the dissolvable substrate. Molten soap can then be applied to theprinted base layer so as to embed the image in the solid soap, asdescribed herein. In at least one embodiment, the image can be printedusing a flat-bed printer as known in the art adapted to use inks asdescribed herein, and adapted to print on an object having at least thethickness of the base layer of solid soap and any background layers oradhered dissolvable substrate.

In at least one embodiment, the solid soap containing the embedded imagecan be formed as an individual bar or cake of soap in a mold, or can becut to a desired size and shape. In at least one embodiment, the solidsoap containing the embedded image can be formed as a sheet or slab ofsolid soap, which can be cut into individual bars or cakes of soap. Insuch embodiments, a number of individual image layers or soap-encasedimage layers may be embedded in the sheet or slab of solid soap, suchthat each individual bar or cake contains an image when cut from thesheet or slab.

The embodiments described herein are intended to be illustrative of thepresent compositions and methods and are not intended to limit the scopeof the present invention. Various modifications and changes consistentwith the description as a whole and which are readily apparent to theperson of skill in the art are intended to be included. The appendedclaims should not be limited by the specific embodiments set forth inthe examples, but should be given the broadest interpretation consistentwith the description as a whole.

The invention claimed is:
 1. A method of producing a solid soapcontaining at least one image embedded therein, the method comprising:printing a printed image on a base layer of solid soap, wherein theprinted image is printed using a flatbed printer; applying molten soapto the printed base layer; and allowing the soap to harden so as toembed the printed image within the solid soap.
 2. The method of claim 1wherein the printed image is an image having a print resolution of atleast 150 dots per inch.
 3. The method of claim 1 wherein the printedimage is a full color image having a print resolution of at least 150dots per inch.
 4. The method of claim 1 wherein the printed image is athree-dimensional image.
 5. The method of claim 1 wherein the printedimage is printed on a background layer disposed on the base layer ofsolid soap.
 6. The method of claim 1 wherein the printed image isprinted using inks that are safe for contact with human skin.
 7. Themethod of claim 6 wherein the inks are edible inks.
 8. The method ofclaim 1 wherein the solid soap is selected from a slab, a sheet and anindividual bar or cake.
 9. The method of claim 1 wherein the at leastone image comprises a plurality of images.